After a long day clearing weeds from the backyard and refreshing the garden beds, I wanted a reward that didn’t involve salad or sandwiches. The dirt was still under my nails, but the sun was just starting to dip, and the kids were all out tossing a ball, hungry but happy. My husband was fiddling with the smoker like it was a second language, so I figured, let’s give it something to say.
I’d saved a recipe I saw on Pinterest a while ago, where someone stuffed manicotti shells with meat and wrapped them in bacon. The photo was so bold and golden and glossy, it stuck in my brain like a bookmark. I didn’t have time to boil pasta or roll out dough, but I had the shells, the meat, and the bacon. That’s all it takes to make something amazing.
The filling came together fast, ground beef, sausage, a bit of onion, cheddar, cream cheese, a chopped jalapeño for bite, and a good splash of barbecue sauce to pull it all together. I stuffed the dry shells carefully, wrapped them up tight in bacon, and gave each one a brush of sauce like it was paint on canvas.
Two hours later, the smell drifting out into the yard stopped the kids in their tracks. Dinner had turned into an event. Messy fingers, smoky smiles, and empty plates told me everything I needed to know.
Short Description
Smoked Shotgun Shells Bacon are cheesy, meaty manicotti shells stuffed with a savory beef and sausage filling, wrapped in bacon, brushed with barbecue sauce, and smoked to crispy, tender perfection.
Key Ingredients
For the Shells
-
16 ounces manicotti shells (two 8-ounce boxes)
For the Meat Mixture
- 1.5 pounds ground beef
- 1 pound hot Italian sausage
- 1 medium onion, finely diced
- 2 cups sharp cheddar cheese
- 6 ounces cream cheese
- 1 jalapeño, finely diced
Seasonings
- 2 teaspoons Slap Ya Mama seasoning
- 2 teaspoons garlic powder
- 2 teaspoons black pepper
- 1 teaspoon red pepper flakes
Other Ingredients
- 1/3 cup barbecue sauce (for the filling)
- 32 ounces bacon (two 16-ounce packages, or more as needed)
- Additional barbecue sauce (for brushing)
Tools Needed
- Large mixing bowl
- Spoon or piping bag (for stuffing)
- Knife and cutting board
- Brush for basting
- Baking sheet or tray
- Smoker or pellet grill (set to 250°F)
- Tongs
Cooking Instructions
Step 1: Prep the Filling
In a large bowl, mix ground beef, sausage, onion, cheddar, cream cheese, jalapeño, and seasonings. Add 1/3 cup of barbecue sauce. Use your hands to combine gently. Don’t overmix—just enough to bring everything together.
Step 2: Stuff the Manicotti Shells
Take uncooked manicotti and fill from both ends with the meat mixture using a small spoon or your fingers. Press gently to pack it in, avoiding air pockets. Be careful not to crack the shells.
Step 3: Wrap in Bacon
Wrap each stuffed shell with bacon, fully covering it. Use one or two slices, overlapping slightly to cover the ends and help hold everything together. Secure with toothpicks if needed.
Step 4: Baste with Sauce
Brush each wrapped shell lightly with barbecue sauce. This first layer will caramelize while smoking.
Step 5: Smoke the Shells
Preheat your smoker to 250°F. Place shells directly on the clean smoker grates or over a foil-lined tray. Smoke for 60 minutes, then flip each one. Baste with more sauce, then smoke for another 60–75 minutes until the bacon is crisp and the filling is cooked through.
Step 6: Serve and Enjoy
Remove from the smoker and let rest for 5 minutes. Serve hot with extra barbecue sauce on the side.
Why You’ll Love This Recipe
Flavor Explosion: Smoky bacon, spicy sausage, melty cheese—every bite packs a punch.
Crowd Favorite: Perfect for parties, tailgates, and backyard get-togethers.
No-Boil Hack: No need to pre-cook the pasta—it softens beautifully in the smoker.
Make Ahead Friendly: Prep the night before and smoke the next day.
Hands-On Fun: Great recipe to make with family or friends—it’s hands-on and satisfying.
Mistakes to Avoid & Solutions
Overstuffing the Shells
Problem: Shells split during stuffing.
Solution: Use a gentle hand and fill from both sides to ease pressure.
Cracked Pasta
Problem: Manicotti breaks before or during stuffing.
Solution: Handle uncooked shells with care. Avoid older pasta boxes that might be brittle.
Bacon Unraveling
Problem: Bacon comes loose while smoking.
Solution: Overlap the ends and secure with toothpicks if needed.
Uneven Cooking
Problem: Bacon gets too crispy while the filling is still raw.
Solution: Use indirect heat and rotate shells halfway through smoking.
Too Dry
Problem: Shells turn tough or dry.
Solution: Baste with extra sauce during the second half of smoking and avoid overcooking.
Serving and Pairing Suggestions
Serve hot with extra barbecue sauce for dipping.
Pair with baked beans, coleslaw, or smoked corn on the cob.
For game day, cut them in half and serve on a platter with toothpicks.
Add a fresh cucumber salad or pickle spears on the side to balance the richness.
Great alongside cold beer, sweet tea, or a smoky bourbon cocktail.
Storage and Reheating Tips
Refrigerate: Store in an airtight container for up to 3 days.
Freeze: Wrap tightly in foil or plastic, then freeze in a freezer-safe bag. Keeps up to 1 month.
Reheat in Oven: Bake at 325°F for 15–20 minutes until heated through.
Reheat in Air Fryer: 350°F for 8–10 minutes for crisp bacon.
Avoid Microwave: It softens the bacon and can make the shell rubbery.
FAQs
1. Can I use different pasta?
Manicotti works best, but large cannelloni shells can be a substitute if needed.
2. Do I need to boil the pasta first?
Nope! The smoker’s heat softens the shells while they cook.
3. What’s the best wood for smoking?
Hickory or applewood give great balance—smoky but not overpowering.
4. Can I use mild sausage instead of hot?
Absolutely. Adjust the spice level to your taste.
5. How do I know when they’re done?
The bacon will be golden and crisp, and the internal temp of the meat should reach 160°F.
Tips & Tricks
Use a piping bag or zip-top bag with the corner snipped to stuff the shells more easily.
Let the filled shells rest 15 minutes before wrapping in bacon—they’ll be firmer and easier to handle.
For extra heat, add diced habanero or a dash of cayenne.
If bacon isn’t crisping, increase smoker temp to 275°F for the last 15 minutes.
Try wrapping in thick-cut pepper bacon for bolder flavor.
Recipe Variations
Tex-Mex Style
Use chorizo instead of sausage, add black beans and a sprinkle of cumin. Use chipotle BBQ sauce for smoky heat.
Breakfast Bombs
Replace beef with breakfast sausage. Add scrambled eggs and shredded hash browns. Wrap in maple bacon and top with hot sauce.
Mac and Cheese Fillings
Stuff with mac and cheese and chopped brisket. Wrap in bacon and brush with sweet BBQ sauce.
Hawaiian Twist
Add diced pineapple and teriyaki glaze to the filling. Wrap in hickory-smoked bacon and brush with pineapple BBQ sauce.
Meatless Option
Use plant-based ground and sausage, dairy-free cheese, and your favorite vegan bacon. Smoke as usual, just adjust cook time for texture.
Final Thoughts
That backyard dinner felt more like a celebration than a regular weeknight meal. We didn’t light candles or set the table fancy, but it didn’t matter. With smoky bacon shells crackling on the plate and everyone reaching in for seconds, it felt like we’d bottled summer and served it hot.
I may have started the day planting vegetables, but I ended it dishing out smoked pasta bombs that left no leftovers. Some recipes don’t need a big story behind them—they just need a hungry crowd and a little smoke in the air.
Smoked Shotgun Shells Bacon
Ingredients
For the Shells
- 16 ounces manicotti shells two 8-ounce boxes
- For the Meat Mixture
- 1.5 pounds ground beef
- 1 pound hot Italian sausage
- 1 medium onion finely diced
- 2 cups sharp cheddar cheese
- 6 ounces cream cheese
- 1 jalapeño finely diced
Seasonings
- 2 teaspoons Slap Ya Mama seasoning
- 2 teaspoons garlic powder
- 2 teaspoons black pepper
- 1 teaspoon red pepper flakes
Other Ingredients
- ⅓ cup barbecue sauce for the filling
- 32 ounces bacon two 16-ounce packages, or more as needed
- Additional barbecue sauce for brushing
Instructions
- Mix ground beef, sausage, onion, cheeses, jalapeño, seasonings, and 1/3 cup barbecue sauce in a large bowl. Combine gently—don’t overmix.
- Fill uncooked manicotti from both ends with the meat mixture using a spoon or fingers. Pack gently to avoid cracking.
- Wrap each shell fully in bacon, overlapping ends. Use one or two slices per shell. Secure with toothpicks if needed.
- Lightly brush each wrapped shell with barbecue sauce.
- Preheat smoker to 250°F. Place shells on grates or foil tray. Smoke 60 minutes, flip, baste again, and smoke 60–75 more minutes until bacon is crisp and filling is cooked.
- Let rest 5 minutes. Serve hot with extra sauce.
